AFP Composite Lay-Up Over Unsupported Aircraft Panel Slots
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional manufacturing process of aircraft panels using composite materials is complex and time-consuming due to the need for reaction mandrels and auxiliary supports, which increase lead time and recurrent costs while introducing variability and potential errors.
Innovation Solution
A method for automatic lay-up of composite materials directly over integrated components like stringers or frames without auxiliary supports, using optimized tow tension and reduced compaction pressure with AFP machines to ensure accurate deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reaction mandrels and auxiliary supports are used during AFP machine pressure application, then the composite skin can be properly formed over integrated components, but the manufacturing process becomes complex and time-consuming with increased lead time and costs
Solution Approach 1:
The invention extracts and eliminates the reaction mandrel and auxiliary support tools from the manufacturing process. By directly laying up composite material over the unsupported slot of the integrated component, the patent removes the need for these auxiliary elements, thereby simplifying the manufacturing process while maintaining the ability to form the composite skin accurately
Solution Approach 2:
The integrated component serves itself by providing the necessary support structure without requiring external reaction mandrels. The component's own geometry and the controlled AFP machine parameters enable the composite material to be properly formed directly on the component, making the system self-sufficient
2Reliability
If reaction mandrels and auxiliary supports are used during lay-up, then proper support is provided during AFP machine pressure application, but lead time and recurrent costs increase
Solution Approach 1:
The invention removes the reaction mandrel extraction step from the process flow. By eliminating this auxiliary element entirely, the patent reduces the number of operations required (placement, positioning, and extraction of mandrels), thereby reducing lead time while maintaining support stability through direct deposition control
Solution Approach 2:
The invention enables continuous lay-up operation without interruption for mandrel extraction or repositioning. The AFP machine can continuously deposit composite material over the integrated component, maintaining uninterrupted production flow and reducing total manufacturing time
3Manufacturing precision
If reaction mandrels are used to compensate for pressure, then accurate tow placement is achieved, but the process requires precise coordination and handling that introduces variability
Solution Approach 1:
The integrated component provides its own geometric reference and support structure, eliminating the need for separate reaction mandrels that require precise coordination. The component's fixed geometry serves as the reference for tow placement, reducing human intervention and associated variability
Solution Approach 2:
The invention replaces the mechanical reaction mandrel system with a controlled force application system. By adjusting AFP machine parameters (roller pressure, tow tension, deposition speed), the patent achieves accurate tow placement through controlled mechanical forces rather than physical contact with auxiliary mandrels, thereby reducing coordination complexity and variability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the workflow, reduces lead time and costs, enhances flexibility, and maintains product quality by eliminating the need for reaction mandrels and other auxiliary tools.
Implementation Method 1
adjusting the force applied to the tow with the AFP machine during deposition over the unsupported slot to compensate the lack of auxiliary support tools
Implementation Method 2
reducing a compaction pressure applied to the tow with the AFP machine while increasing the tow tension during deposition over the unsupported slot
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method (100) for manufacturing an aircraft panel that comprises a composite skin (240) with integrated components (220) (stringers/frames) having unsupported slots (220a), the method comprising obtaining (110) a male tool with the integrated component (220), laying up (120) the composite skin directly over the unsupported slots of the integrated component (220) with an automated fiber placement, AFP machine that provides tow deposition, wherein the integrated component (220) lack auxiliary support tools and adjusting (130) the force applied to the tow with the AFP machine during deposition over the unsupported slots to compensate the lack of auxiliary support tools.